Headless suspended lass transfer and reaction tower

ABSTRACT

A headless suspended mass transfer and reaction tower system used for the scrubbing, stripping or chemical reaction between gases and liquids. The system comprises an elongated shell having a closed top end and a suspension member configured to suspend the tower from an external suspension support. Various embodiments of the system can be adapted for the purposes of chemical vent scrubbing, absorption, odor abatement, gas-liquid chemical reactions, or similar processes. The tower can be operated in the classical counter current or concurrent flow modes, under pressure, or in a partial vacuum.

This application is a continuation-in-part of U.S. patent applicationSer. No. 12/850,519, filed on Aug. 4, 2010, now U.S. Pat. No. 8,414,841,the entire contents of which are incorporated herein by this reference.

BACKGROUND

Conventional mass transfer or chemical reaction packed towers (alsoknown as columns) typically comprise a rigid shell, internal towercomponents and packing. Shells are constructed with materials such asmetals, plastics, composites or other rigid materials. The internaltower components typically consist of miscellaneous process equipmentsuch as liquid gas/distributors, packing supports, mist eliminators,spray nozzles, instruments and the like which are installed in or on thetower to facilitate process requirements such as the management ofliquid and gas flows. The packing typically consists of either random orstructured packing, separate or in combination, or trays (plates) knownin the industry. Other external ancillary equipment such as fans, pumps,lines, tanks are connected to the tower to complement the processrequirements. Conventional packed towers are supported by the shellbearing on the floor or from a structure designed for a similar purpose.The internals tower components and packing are typically supported atdifferent locations from nozzles or from the inside of the tower'sshell. Conventional towers are mostly permanently installed and noteasily portable.

There is a need for a portable light weight tower system capable ofbeing transported in a compact manner and installed at a variety oflocations using equipment standard in the industry. The invention isdirected at overcoming one or more of the problems by providing alightweight, sectional, collapsible, portable tower capable of beinginstalled in almost any industrial setting.

SUMMARY OF THE INVENTION

The system is a suspended tower, and components thereof. A suspendedtower system according to principles of the invention permits masstransfer or chemical reactions within a system, that can be transported,set up, and operated in either countercurrent or concurrent flow formatsin a variety of locations, conditions, and environments. The suspendedtower allows typical mass transfer operations such as absorption orstripping. The system generally comprises a top head and a bottom headconnected by a soft shell containing, suspended packing, wherein theentire system is suspended by a suspension means located on the tophead. In various embodiments described below, the system can furthercomprise upper tension hubs, lower tension hubs, internal towercomponents, internal suspension lines and external suspension lines.Collectively, the top head, bottom head, the packing, and shell connectto form a suspended tower.

The top head provide structural support for the shell, suspendedpacking, tension hubs, and suspension lines. The top head is a rigidportion of the tower and is constructed of metal, plastic, composites orother rigid materials and it provides a location for the installation ofinternal tower components such as spray nozzles, liquid distributors,mist eliminators, packing bed limiters, instrumentation or the like. Thetop head houses the upper tension hub. The top head comprises a locationfor bracing and sealing the shell. Lateral lugs can be added for bracingthe top head to reduce lateral movement. The design of the top head willvary depending of the demands of the process for which the system isdesigned.

The bottom head is a rigid portion of the tower constructed of metal,plastic, composites or other rigid materials. In most embodiments, theweight of the bottom head and its contents will provide the tensilerequirements of the system for bracing and shaping the shell. The bottomhead houses the lower tension hub. The bottom head affords a locationfor the installation of internal tower components, such as liquid andgas nozzles, instrumentation and the like. The bottom head comprise alocation for bracing and sealing the shell. The bottom head comprises areceptacle to collect the liquid falling down the tower's liquidmanagement system.

The upper tension hub and lower tension hub fit inside the top head andbottom head, respectively. The tension hubs are designed to provide alocation for bracing the suspended packing and internal suspensionlines. The tension hubs transfer the tensile force between the top andbottom heads. In one embodiment, the tension hubs are annular rigidrings having slots capable of mating with tension hub lugs located onthe inside surface of the top head and bottom head, respectively. Inother embodiment, the tension hubs may take different shapes dependingof the design requirements. The design of the tension hubs can include acombination of functions in addition to bracing such as liquid/gasdistribution, bed limiters, mist collectors or the like.

Generally, the shell is constructed of pliable or lightweight rigidmaterials allowing portability and ease of handling. The shell servesthe functions of joining the top head and bottom head, containing theprocess gasses and liquids within the tower system, providing a spacefor the suspended packing bundle, supporting the packing in certainapplications, and providing the flow shape of the tower. The shell has ameans for a removable top attachment, which is any means for removablyattaching the top of the shell to the top head or adjacent support, suchas the support means on a connector head. The bottom of the shellcomprises a means for a removable bottom attachment, which is any meansfor attaching the bottom of the shell to the bottom head or connectorhead. The shell may provide all, some or none of the weight bearingrequirements of the tower.

The shape of the shell is maintained by stretching the shell materialbetween the top head and bottom head. Under normal conditions, the shellis under tension induced by the weight of the bottom head, and the shellconforms to its natural catenary shape. In another embodiment, the shapeof shell can be enhanced by the use of battens installed on the surfaceof the shell.

In order to form a leak-resistant seal between the shell and the bottomhead, the shell comprises a liquid chute, which is an annular, taperedflap-like portion near the bottom of the shell. The chute directs theliquid flow away from the seal made by the bottom sealing cuff of theshell and the bottom head and channels the liquid into the bottom head.

The shell can be increased in length by connecting one or more shellstogether using the suspension connector heads. The connector headscomprise one or more connector tension hubs and provide connectivity fortower internal components and ancillary equipment. The connector headscomprise one or more shell support means as described above in thecontext of the heads. In the suspended tower having multiple shellsegments, a connector head can be disposed between an upper shellsegment and a lower shell segment. The upper segment attaches to asupport means on the connector head via the bottom support means on theupper shell segment. The lower shell segment attaches to a support meanson the connector head via the top attachment means on the lower shellsegment. The attachments are made by similar methods and means as thosedescribed above in the context of attaching the shell to the heads.

The packing is suspended from the top head, from the shell, or acombination thereof. The suspended packing is used to provide a spacefor the intimate contact between the liquid and gas for mass transfer orchemical reaction to occur. The suspended packing in the interior of thetower can be installed by several methods known in the art.

In another embodiment, the suspended tower comprises a soft shell and asuspension member, without a top head or a bottom head. This embodimentpromotes simplicity of the component parts, as well as ease of transportand installation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an exploded view of the mass transfer tower system.

FIG. 2 shows an elevation view of an exemplary, partially disassembledsuspended mass transfer tower.

FIG. 3 is an elevation view of a typical top head.

FIG. 4 is a top view of a typical top head.

FIG. 5 is a bottom view of a typical top head.

FIG. 6 is an elevation view of a typical bottom head.

FIG. 7 is a top view of a typical bottom head.

FIG. 8 is a bottom view of a typical bottom head.

FIG. 9 is a partial cross section view of a top head, showing the uppertension hub and the tension hub lugs.

FIG. 10 is an elevation view of a typical shell.

FIG. 11 is an elevation view of a typical top head showing one exampleof means of shell support.

FIG. 11A is a cross section view of one embodiment of a shell supportmeans on a top head.

FIG. 12 is a top view of one embodiment of a top head having the supportmeans shown in FIGS. 11 and 11A.

FIG. 13 is an elevation view of the top head showing one embodiment ofthe top shell attachment means.

FIG. 14 is an elevation of the top head showing one embodiment of thetop attachment means.

FIG. 14A is an elevation of the top head showing one embodiment of thetop attachment means in which bolts are used to attach the shell to theheads.

FIG. 15 is an elevation view of the suspended mass transfer tower systemhaving one embodiment of the battens.

FIG. 16 is an elevation view of the suspended mass transfer tower systemhaving one embodiment of the battens.

FIG. 17 is an elevation view of the suspended mass transfer tower systemhaving one embodiment of the battens.

FIG. 18 is an elevation view of a typical top head showing the sealingbands securing the cuff of the shell.

FIG. 18A is an enlarged view of a typical arrangement of a shell'ssealing cuff, sealing gasket, top head and sealing bands.

FIG. 19 is an elevation view of the bottom head showing the sealingbands securing the cuff of the shell and the liquid chute.

FIG. 19A is an enlarged view of a typical arrangement of a shell'ssealing cuff, sealing gasket, bottom head and sealing bands.

FIG. 20 is an elevation view of one embodiment of the top attachmentmeans.

FIG. 21 is an elevation view of the bottom head showing the fluid flowfrom the shell to the bottom head through the liquid chute.

FIG. 21A is an enlarged view of the liquid chute, shell's sealing cuff,sealing gasket and bottom head.

FIG. 22 is an elevation view of a connection head.

FIG. 23 is a cross section view of a typical connection head.

FIG. 24 is an exploded elevation view of a suspended tower system havingmultiple shell segments connected in series.

FIG. 25 is a cross section view of the shell, showing typical sealridges.

FIG. 26 is an elevation view of one embodiment of suspended packingsuspended within the tower system.

FIG. 26A is an elevation view of an alternate embodiment of suspendedpacking supported within the shell portion of the tower system.

FIG. 27 is an elevation view of the steps of attaching the suspendedpacking via the upper tension hub to the top head and raising the tophead and suspended packing.

FIG. 28 is an elevation view of the step of preparing the shell forattachment to the top head.

FIG. 29 is an elevation view of the steps of connecting the top head tothe shell and preparing the bottom head for installation.

FIG. 30 is an elevation view of the steps of installing the bottom headsecuring the suspended tower.

FIG. 31 shows an elevation view of one embodiment of the industrialconnectivity of ancillary equipment used for a typical suspended masstransfer tower system.

FIG. 32 shows a typical headless suspended mass transfer tower systemwith a portion of the shell removed to expose the packing inside theshell.

FIG. 33 shows a partial headless suspended mass transfer tower systemwith a portion of the shell pulled back to expose the tension head,internal structure, and packing.

Those skilled in the art will appreciate that the figures are notintended to be drawn to any particular scale; nor are the figuresintended to illustrate every embodiment of the invention. The inventionis not limited to the exemplary embodiments depicted in the figures orthe shapes, relative sizes, or proportions shown in the figures.

DETAILED DESCRIPTION

Referring to the Figures, various embodiments of an exemplary suspendedtower system, and components thereof, are shown. A suspended towersystem according to principles of the invention permits mass transfer orchemical reactions between liquid and gases within a portable systemthat can be transported, set up permanently or temporarily, and operatedin a variety of locations, conditions, and environments. The embodimentsdisclosed herein are meant for illustration and not limitation of thesystem. An ordinary practitioner will understand that it is possible tocreate other variations of the following embodiments without undueexperimentation.

Suspended Tower System

Referring to FIGS. 1 and 2, the system generally comprises a top head 10and a bottom head 12 connected by a soft shell 15 containing a suspendedpacking bundle 16, wherein the entire system is suspended by a means forsuspension 11 located on the top head 10. In various embodimentsdescribed below, the system can further comprise upper tension hubs 17,lower tension hubs 20, internal suspension lines 18, and externalsuspension lines 19. Collectively, the top head 10, bottom head 12, thesuspended packing 16 and shell 15 connect to form a suspended tower, asdescribed below.

Referring to FIGS. 3-8, the top head 10 and bottom head 12 are anintegral part of the mechanical support of the tower. They providestructural support for the shell 15, suspended packing 16, upper tensionhubs 17, lower tension hubs 20, internal suspension lines 18, andexternal suspension lines 19 and miscellaneous tower components. The tophead 10 supports the weight of the entire system, which is suspendedfrom the suspension means 11. The bottom head 12 can be anchored viaanchoring means 13 to the floor, external structures or a ballast toprovide added stability to the entire tower.

The top head 10 has two main functions, which are first to provide astructure from which to suspend the tower, and second, to provide aplace for the installation of internal tower components and provideconnectivity to miscellaneous ancillary process equipment. Referring toFIGS. 3-5, the top head 10 is a rigid portion of the tower and isconstructed of metal, plastic, composites, other rigid materials or acombination thereof. The top head 10 incorporates a means for suspension11, such as lugs, hooks, clasps, anchors, or the like. The top head 10has one or more suspension means 11 to apply the tension necessary tolift and suspend the entire tower system. The top head 10 can furthercomprise lateral lugs 23 that can be spaced laterally for bracing thetop head 10, thereby reducing lateral or twisting movement. The top head10 is laterally braced by attaching the lateral lugs 23 using lateralbraces (not shown), such as rods or cables to a structure. The top head10 provides a location 44 for the installation internal tower componentssuch as liquid distribution, liquid distributors trays, misteliminators, packing bed limiters, instrumentation and the like. The tophead 10 also affords the installation of process nozzles 31 for theinstallation of internal tower components or to provide connectivity toancillary process equipment 206. The remaining design of the top head 10will vary depending of the demands of the process for which the systemis designed.

The bottom head 12 has two main functions, which are first to provide astructure to anchor the suspended tower and second, to provide a placefor the installation of internal tower components and provideconnectivity to miscellaneous ancillary process equipment. As shown inFIGS. 6-8, the bottom head 12 is a rigid portion of the towerconstructed of metal, plastic, composites, other rigid materials or acombination thereof. The bottom head 12 has one or more anchoring means13 to apply the tension necessary to shape the shell 15 or anchor thesuspended tower. The bottom head 12 can further comprise lateral lugs 23that can be spaced laterally for bracing the bottom head 12, therebyreducing lateral or twisting movement. The bottom head 12 is laterallybraced by attaching the lateral lugs 23 using lateral braces (notshown), such as rods or cables to a structure. The anchoring lug 13 orlateral braces 23 can also be attached to ballasts. The bottom head 12affords a location 44 for the installation of different internal towercomponents such as the lower tension hub 20, liquid chute 25, spraynozzles, gas distributors, packing support trays and the like. Thebottom head 12 also affords the installation of process nozzles 31 forthe installation of internal tower components or to provide connectivityto ancillary process equipment 206. The bottom head 12 comprises areceptacle to collect the liquid falling down the tower's liquidmanagement system.

As shown in FIG. 9, the upper tension hub 17 and lower tension hub 20fit inside the top head 10 and bottom head 12, respectively. The tensionhubs 17, 20 are designed to provide a location for retaining andanchoring the suspended packing 16 and internal suspension lines 18. Inone embodiment, the tension hubs 17, 20 are annular rigid rings havingslots 40 capable of mating with tension hub lugs 45 located on theinside surface of the top head 10 and bottom head 12, respectively. Thelugs 45 can be welded or otherwise firmly attached to the interior ofthe heads 10, 12. The tension hubs 17, 20 are attached by inserting thehub into the respective head, aligning the slots 40 of the tension hubs17, 20 with the tension hub lugs 45, and twisting the tension hubs 17,20 such that the lugs 45 are securely and removably seated within theslots 40. Alternatively, the tension hubs 17, 20 can be bolted or weldedin place. Several other embodiments of the tension hubs can be used. Forexample, the tension hubs could comprise bars forming a cross, grids, orracks, as desired.

Generally, the shell 15 is constructed of pliable or lightweight rigidmaterials allowing portability and ease of handling. The shell 15 servesthe functions of joining the top head 10 and bottom head 12, containingthe process gasses and liquids within the tower system, providing aspace for the suspended packing 16, supporting the packing in certainapplications, and providing the flow shape of the tower. Referring toFIG. 10, the shell 15 can be constructed of a combination of pliablematerials such as polymer films, fabrics, rubber, membranes or acombination thereof. A single layer or multiple layers of similar ordifferent materials can be used to fabricate the shell 15. One of thelayers is typically of a stretch resistant material used for tensioningand shaping. Other layer materials can be applied as lining for theshell 15 to provide chemical, erosion or fire resistance or for sealingpurposes. Insulating layers can be used as required for the design.Multiple layers can be joined together by gluing, stitching, thermalfusing, vulcanizing or any other joining methods or combinationsthereof. Supporting lines can be embedded within the layers of the shell15 to provide additional tensile capacity. Access ports can be installeddirectly on the shell 15 to add or remove packing. In one embodiment,the top and bottom of the shell 15 comprise sealing cuffs 21 that snuglyfits over the top 10 and bottom 12 heads to prevent process leaks.

The shell 15 can be detached from the top head 10 and bottom head 12 asdescribed below. In embodiments where the shell 15 is constructed ofpliable materials, when the shell 15 is detached from the heads 10, 12and packing 16, it can be rolled, folded, or otherwise collapsed topromote easier handling and transportation. Depending on the size andconfiguration of the tower system, the collapsed shell 15 and the heads10, 12 with the suspended packing 16 can be easily transported to nearlyany location.

The shell 15 has a means for a removable top attachment 33, which is anymeans for removably attaching the top of the shell 15 to the top head 10or to a connection head 26 as described below. Referring to FIGS. 11-14,the top attachment means 33 can comprise a variety of attachment methodssuch as ties, hook-and-loop closures, buttons, hooks, bolts, or anyother kind of releasably secured fastener. The heads 10, 12 comprise ameans for shell support 50, such as hooks, rings, clasps, anchors, orthe like. In one embodiment, the support means 50 comprises a ring 51supported by wedge-shaped gussets 53 attached to the outer surface ofthe top head 10 or bottom head 12, where the attachment could be made bya weld, chemical bond or other. The ring 51 is seated over the gussets53 such that the tension pull created by the shell 15 forces the ring 51and gussets 53 to support the weight. The gussets 53 are radially spacedabout the circumference of the heads 10, 12, which allows radial gaps 54for securement of the attachment means 33, 34. In this embodiment, theattachment means 33, 34 could be straps secured with hook-and-loopclosures, hooks, straps, fastener rings, or the like. In anotherembodiment attachment means 33, 34, shown in FIG. 14A, bolts are used toattach the shell 15 to the heads 10, 12 without using a ring structure51.

The shell 15 comprises a means for a removable bottom attachment 34,which is any means for removably attaching the bottom of the shell 15 tothe bottom head 12 or to a connector head 26 as described below. Thebottom attachment means 34 can comprise a variety of attachmentstructures such as ties, hook-and-loop closures, buttons, hooks, bolts,or any kind of releasably secured fastener similar to those used for thetop attachment means 33.

FIGS. 15-17 show several embodiments for the shape of the shell 15. Theshape is maintained by stretching the shell 15 between the top head 10and bottom head 12. Under normal conditions, the shell 15 is undertension induced by the weight of the bottom head 12, and the shell 15conforms to its natural catenary shape. In many embodiments, the weightof the bottom head 12 and its contents can provide the tensilerequirements for the system as described above.

In another embodiment, the shape of shell 15 can be enhanced by the useof battens 35 installed on the surface of the shell 15. The battens 35can be adjusted as desired to alter the shape of the shell 15 foroptimum performance of the process within the tower. For example, thebattens 35 could be circular rings 36 placed around the exterior of theshell 15 to maintain the uniform circular section. These circular rings36 can prevent collapse of the shell 15 where the mass transfer systemis operated under a partial vacuum. In another embodiment, the battens35 could be vertical vanes 37 providing lateral stiffness to the shell15. In another embodiment, the battens 35 could comprise externalsuspension lines 19 running through sleeves 39 on the external portionof the shell 15.

As shown in FIGS. 18-20, the top of the shell 15 comprises a sealingcuff area 21 forming a seal on the top head 10. The bottom of the shell15 comprises a sealing cuff section area 21 forming a seal on the bottomhead 12. The seals are formed by installing sealing bands 24 or othermeans of restraint on the cuff 21 section. The sealing bands 24 aretightened over the exterior of the top head 10 and bottom head 12,respectively, to seal in the process fluids.

In another embodiment, shown in FIG. 20, the top attachment means 33 andbottom attachment means 34 can comprise flanges 41 that mate to and forma seal against a rims or flanges installed on top head 10 and bottomhead 12, respectively. This seal can be formed by tightly bolting orotherwise securing the flanges 41 to the respective flange or rim in thetop head 10 and bottom head 12. This type of seal is conventional inindustrial applications.

Referring to FIG. 21, in order to form a leak-resistant seal between theshell 15 and the bottom head 12, the shell 15 comprises a liquid chute25, which is an annular, tapered flap-like portion near the bottom ofthe shell 15. The chute 25 directs the liquid flow away from the bottomseal created by sealing cuff 21 and the bottom head 12 and channels theliquid into the bottom head 12. The chute 25 can be inserted into theshell 15 or integral therewith. Optionally, a sealing gasket 42 can beplaced between the cuffs 21 and the heads 10, 12. The sealing gasket 42is any device or article capable of forming a seal between the upper orlower sealing cuff 21 and the top head 10 or bottom head 12. Forexample, the sealing gasket 42 could be an elastomer ring or band,rubber gasket, or the like. The liquid chute can be reinforced withbattens 35 or braced to retain the integrity of its shape.

As shown in FIGS. 22-24, the shell 15 can be increased in length byconnecting one or more shells 15 together using the suspension connectorheads 26. The connector heads 26 comprise means for connecting to theshells 15 and provide a place for tower internals and equipment 31. Thebracing of the shell 15 is similar to the top head 10 and bottom head12. The connector heads 26 comprise one or more shell support means 50such as described above in the context of the heads 10, 12. In thesuspended tower having multiple shell 15 segments, a connector head 26can be disposed between an upper shell segment 15 a and a lower shellsegment 15 b. The upper segment 15 a attaches to a support means 50 onthe connector head 26 via the bottom support means 34 on the uppersegment 15 a. The lower segment 15 b attaches to a support means 50 onthe connector head 26 via the top attachment means 33 on the lower shellsegment 15 b. The attachments are made by similar methods and means asthose described above in the context of attaching the shell 15 to theheads 10, 12.

As shown in FIG. 25, circular seal ridges 27 can be attached to theinside of the shell 15 to provide effective contact between the innerwall of the shell 15 and the suspended packing 16. The seal ridges 27are annular or semi-annular flaps protruding towards the interior of theshell. As described below, the suspended packing 16 is supported orsuspended inside the shell 15. The seal ridges 27 provide a means bywhich the liquid flowing down the inside of the shell 15 can contact thesuspended packing 16 and gas rising inside the shell 15. Effectivecontact is required to enhance liquid-gas interaction and to reduce walleffect disturbances that can reduce the efficiency of the tower. Theaforementioned contact also reduces the possibility of liquid channelingdown the inside wall of the shell 15.

Depending on the particular application of the tower system, the shell15, tension hubs 17, 20, and support lines 18, 19 provide redundant loadpaths to support the dead weight of the tower. In some embodiments ofthe system, the shell 15 is capable of providing sufficient tensilestrength to support the weight of the system without additional tensilesupport from other members. In other embodiments, internal suspensionlines 18 or external suspension lines 19 can share or support the entiretensile load. As shown in FIG. 2, the internal suspension lines 18 arecables or rigid rods that are used in the interior of the towers, whichthe exterior suspension lines 19 are disposed on the exterior of thetower. The suspension lines 18 are attached to the tension hubs 17, 20in the top head 10 and bottom head 12, respectively. The externalsuspension lines 19 are attached to 50 or other bracing points on thetop head. The suspension lines 18, 19 can be used to provide lateralstiffness and tensile strength to the tower.

The packing is suspended from the top head 10 via the upper tension hub,from the shell 15, or a combination of the thereof. The suspendedpacking 16 is used to provide a space for the intimate contact betweenthe liquid and gas for process requirements. The suspended packing 16 inthe interior of the tower can be installed by several methods. In oneembodiment, the upper tension hub 17 comprises suspension bars 47 thatserve as hangers for lines 18 supporting the suspended packing 16. Thelines 18 could be cables, ropes, strings, straps, or any like materialthat can resist the tension and the chemicals in the system. As shown inFIG. 26, individual lines 18 can be threaded through the packing 16material, which are suspended and anchored using the tension hubs 17,20.

The suspended packing 16 can be comprised of random or structuredpacking. In one embodiment, a packing bundle or cartridge is made byenclosing random packing in a membrane and suspended using lines 18. Inother embodiments, structured packing can be aligned using suspensionlines 18 and using a retainer base near the bottom of the tower system.FIG. 26A shows an embodiment where packing can be dumped inside theshell 15 which is fitted with a reticulated support 38. In this case,the shell 15 supports the packing in a bag like fashion. Otherwise, thetower can be operated as a spray tower with the internals supported onthe shell or from the top head.

Method of Installation and Use

FIGS. 27-30 show a typical method of installing the system. The methodcomprises the steps of attaching the suspended packing to the top head110, raising the top head and packing bundle 115, preparing the shellfor attachment to the top head 120, connecting the top head to the shell125, preparing the bottom head for installation 130, installing thebottom head 135, securing the suspended tower 140, and connecting theexternal equipment to the suspended tower 145.

In the step of attaching the suspended packing to the top head 110, thetop head 10 is laid on its side while the packing bundle 16 is attached.The upper tension hub 17 is inserted into the top head 10 andtwist-locked, bolted, or otherwise secured into place. As describedabove, the packing bundle 16 and suspension lines 18, 19 can be attachedto the top head 10 as required for the particular application.

In the step of raising the top head and suspended packing 115, asuspension device 100 is attached to the suspension means 11, and thetop head 10 and packing bundle 16 are lifted off of the ground surfaceto a height sufficient to provide the necessary ground clearance forpreparing the shell 15 for attachment to the top head 10.

In the step of preparing the shell for attachment to the top head 120,the shell 15 is placed below and aligned with the elevated top head 10and suspended packing 16. The top attachment means 33 is prepared forattachment to the top head 10, and the shell 15 is prepped for receivingany battens 35 or external suspension lines 19, as the situationrequires.

In the step of connecting the top head to the shell 125, the suspendedpacking 16 and top head 10 are lowered into the shell 15. The topattachment means 33 is secured to the support means 50 on the top head10 such that the shell 15 is securely and removably attached to the tophead 10. All fasteners are secured and all sealing bands 24 aretightened.

In the step of preparing the bottom head for installation 130, the tophead 10, suspended packing bundle 16, and shell 15 are lifted to provideadequate ground clearance to prepare the bottom head 12 forinstallation. The bottom head 12 is position below the shell 15 suchthat the shell 15 will align with the bottom head 12 when the shell 15is lowered.

In the step of installing the bottom head 135, the top head 10,suspended packing 16, and shell 15 are lowered to connect with thebottom head 12. The bottom tension hub 20 is inserted into the bottomhead 12 and twist-locked, bolted, or otherwise secured into place. Thebottom attachment means 34 is connected to the support means 50 on thebottom head 12 such that the shell 15 is securely and removably attachedto the bottom head 12. All fasteners are secured and all sealing bands24 are tightened. As described above, the packing bundle 16 andsuspension lines 17, 18, can be attached to the bottom head 12 asrequired for the particular application. As another optional embodimentin step 135, any suspension lines can be tensioned or stretched. Oncethe suspension lines have been tensioned, the bottom attachment 34 ofshell 15 can be attached to bottom head 12 support means 50 and sealingbands 24 tightened.

In the step of securing the suspended tower 140, the top head 10,suspended packing bundle 16, shell 15, and bottom head 12 are lifted sothat the entire tower system is elevated above the floor or ground.Optionally, one or more anchor lines 49 can be attached to the anchormeans 13 on the bottom head 12, and lateral bracing lines (not shown)are attached to the lateral lugs 23 as desired.

In the step of connecting the external ancillary process equipment tothe suspended tower 145, the external equipment is connected to thesuspended tower system by any manner conventional in the industry. FIG.31 shows that the tower installation configuration will vary dependingon the service required. The external ancillary process equipment mayinclude any combination of circulation pumps 201, circulation tanks 202,fans 208, dosing pumps 204, scrubbing chemical tanks 205, and aplurality of conventional hoses, lines, ducts and conduits 206.

Headless Suspended Tower System

In another embodiment of the suspended mass transfer tower, the systemdoes not need a top head 10 or a bottom head 12 to function properly.Instead, the suspended tower system comprises the basic elements of asoft shell 515 and a suspension member 511 in a baglike manner. In thisembodiment, the packing 516 contributes to shaping and contouring of theshell 515. This embodiment has the added advantages of simplifying therequired component parts of the mass transfer tower by eliminating thetop head 10 and bottom head 12. The weight savings of this embodimentpromotes ease of transport and installation of the headless suspendedmass transfer tower 599.

Referring to FIG. 32, the shell 515 is formed from pliable,stretch-resistant material in an elongated shape having closed top andbottom ends. The shell 515 could be a single piece of material or formedin segments, as described above. To support the headless suspended towersystem 599, the shell 515 is suspended by a suspension member 511attached to the shell 515. The suspension member 511 can be any lug,hook, clasp, anchor, or similar member configured to connect thesuspended tower system to a suspension support of a supporting structureexternal to the tower. In many embodiments, the shell 515 will have asubstantially circular cross sectional shape. However, other crosssectional shapes may be used according to the application of thesuspended tower system 599.

In this embodiment, the shell 515 is constructed of pliable materials,as taught in the embodiments discussed above. The shell 515 serves thefunctions of containing the process gasses and liquids within the towersystem, providing a space for the suspended packing 516, supporting thepacking 516 in certain applications, and providing the flow shape of thetower 599. The shell 515 can be constructed of a combination of pliablematerials such as polymer films, fabrics, rubber, membranes or acombination thereof. In at least one embodiment, the shell 515 comprisesa pliable material adapted to fold when the shell is removed from thesuspension support. The pliable material permits the shell 515 to befolded into a compact form, which promotes ease of transport.

A single layer or multiple layers of similar or different materials canbe used to fabricate the shell 515. One of the layers is typically of astretch resistant material used for tensioning and shaping. Other layermaterials can be applied as lining for the shell 515 to providechemical, erosion or fire resistance or for sealing purposes. Insulatinglayers can be used as required for the design. Multiple layers can bejoined together by gluing, stitching, thermal fusing, vulcanizing or anyother joining methods or combinations thereof. Supporting lines can beembedded within the layers of the shell 515 to provide additionaltensile capacity. Access ports 532 can be installed directly on theshell 515 to add or remove packing. The access ports 532 are disposedwithin the shell and configured to accommodate insertion of packing 516or tower internals, such as nozzles, into the shell.

Under the tension created by suspending the system or vacuum within thesystem, the pliable shell 515 will tend to collapse absent sufficientlateral support. There are many ways to provide lateral support to theshell 515 to assist in maintaining a contour or profile necessary tooperate the chemical and mass transfer processes for which the towersystem 599 is employed. For example, the suspended packing 516 can be asemi-rigid material, such as a foam material, capable of providing ashaping form to the shell 515. Alternately, as shown in FIG. 26A, thepacking 516 can be retained by reticulated supports disposedintermittently along the height of the tower system 599. These “pockets”of packing material 516 tend to create tension in the shell 516, therebyproviding the shell 516 with form and shape.

In another embodiment, the shell 515 is tightly packed with packing 515,which creates a lateral expansion force, thereby creating a lateraltension force in the shell 515. The gravitational force of the densepacking 516 additionally creates a vertical tension force in the shell515. Under these perpendicular tension forces, the shell 515 retains theshape in a baglike manner, as designed for particular mass transferapplications.

In another embodiment, the headless suspended tower 599 comprisesexternal battens for shaping the shell 515 in a manner similar to thatdescribed in previous embodiments. In another embodiment of the headlesstower system 599, the shell 515 can be supported by an internalstructure 550, such as a frame, paneling, inflatable soft shell walls,or the like. This embodiment permits the packing 516 to comprise softermaterial, which may be better suited for certain chemical or masstransfer processes. The internal structure 550 comprises rigid orsemi-rigid elements, such as metals, plastics, or composite materials.Lightweight materials may be preferred for certain applications of thetower system 599. The material for the internal structure 550 should beselected to withstand a harsh corrosive environment inside the towersystem 599.

In another embodiment, shown in FIG. 33, the headless suspended tower599 can comprise a tension hub 517 that serves as a ring-like,structural support member from which to suspend the shell 515 or packingmaterial 516. For example, the shell 515 can be attached to the exteriorof the tension hub 517 in a manner similar to the top attachment meanstaught in embodiments discussed above. For example, the shell 515 has ameans for a removable attachment 533, which is any means for removablyattaching the shell 515 to the tension hub 517. The attachment means 533can comprise a variety of attachment structures, such as ties,hook-and-loop closures, buttons, hooks, bolts, slotted connections, orany other kind of releasably secured fastener. The packing 516 can alsobe suspended from the tension hub 517, such as by attaching the packing516 to lines suspended from the tension hub 517. The tension hub 516provides lateral support to the shell 515, thereby assisting the towersystem 599 in retaining its desired shape and diameter. The tension hub517 can also provide an anchorage point to which the suspension member511 or the internal structure 550 can be attached.

In at least one embodiment, the shell 515 further comprises nozzle ports531 configured to connect process components inside the shell 515 toequipment outside the shell 515. The remaining design of the shell 515will vary depending of the demands of the process for which the systemis designed.

The foregoing embodiments are merely representative of the suspended,mass transfer system and not meant for limitation of the invention. Forexample, one having ordinary skill in the art would understand that manycomponents described herein can be customized for specific applicationsby an ordinary practitioner. Several components of the suspended towermay be altered depending on the chemical process being deployed.Consequently, it is understood that equivalents and substitutions forcertain elements and components set forth above are part of theinvention, and therefore the true scope and definition of the inventionis to be as set forth in the following claims.

What is claimed is:
 1. A suspended tower system capable of performingmass transfers or chemical reactions, said tower system comprising: ashell configured to form an elongated mass transfer tower having aclosed top end; and a suspension member configured to suspend the towerfrom an external suspension support.
 2. The tower system of claim 1,wherein the shell further comprises a pliable material adapted to foldwhen the shell is removed from the suspension support.
 3. The towersystem of claim 2, wherein the shell further comprises battensconfigured to alter the natural catenary shape of the shell.
 4. Thetower system of claim 2, further comprising a tension hub configured toprovide lateral support to the shell.
 5. The tower system of claim 2,further comprising an access port disposed within the shell, said accessport configured to accommodate insertion of packing into the shell. 6.The tower system of claim 2, wherein the shell further comprises nozzleports configured to connect process components inside the shell toequipment outside the shell.
 7. The tower system of claim 2, furthercomprising packing suspended inside the shell.
 8. A suspended towersystem capable of performing mass transfers or chemical reactions, saidtower system comprising: a shell configured to form an elongated masstransfer tower having a closed top end; a suspension member configuredto suspend the tower from an external suspension support; and aninternal structure disposed inside the shell and configured to providestructural support to the shell.
 9. The tower system of claim 8, whereinthe shell further comprises a pliable material adapted to fold when theshell is removed from the suspension support.
 10. The tower system ofclaim 9, wherein the shell further comprises battens configured to alterthe natural catenary shape of the shell.
 11. The tower system of claim9, further comprising a tension hub configured to provide lateralsupport to the shell.
 12. The tower system of claim 9, furthercomprising an access port disposed within the shell, said access portconfigured to accommodate insertion of packing into the shell.
 13. Thetower system of claim 9, wherein the shell further comprises nozzleports configured to connect process components inside the shell toequipment outside the shell.
 14. The tower system of claim 9, furthercomprising packing suspended inside the shell.